Shoe Toe Cap

ABSTRACT

A shoe toe cap for protecting a toe end of a shoe is disclosed. The shoe toe cap has various layers adhered together to form a single piece for use on the shoe toe cap. Adhesive film layers and polyurethane film layers are combined to form the inventive shoe toe cap. A lowermost adhesive film layer is temporarily or permanently adhered to the toe end of the shoe. A series of polyurethane film layers are adhered on top of the lowermost adhesive film layer. The shoe toe cap is abrasion and creep resistant and increases the life of the shoe.

CROSS REFERENCE TO RELATED APPLICATION(S)

This is a non-provisional patent application based on co-pending U.S. Provisional Patent Application Ser. No. 62/077,991 (Attorney Docket No. LD-14-1) previously titled “Shoe Toe Cap”, filed on Nov. 11, 2014, the priority of which is hereby claimed and the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

1. Field of the Invention

The present invention relates to a protector used for the protection of a shoe. More particularly, the present invention relates to a shoe toe cap which increases the durability of the shoe.

2. Description of the Related Art

Various methods have been used in the past to prolong life of the shoes and to protect them from getting damaged. One of the techniques includes the use of a shoe toe cap for footwear. This method is very well documented in the art. The shoe toe cap includes a piece of cloth or polymer or any other suitable material which covers the toe end of the shoe.

Different types of shoe toe caps used on footwear's serve different purposes. For e.g. working boots for factory workers are designs to have steel toe cap to ensure safety from heavy tools and machine parts. Shoes designed for athletes have shoe toe caps made of material which protect and extend the life of the cleats. Children while playing, rub their shoes on a street sidewalk, or on a dirt road, especially the toe end of the shoe. Hence toe caps for shoes worn by children are generally abrasion resistant which prevent scuffing and keep the shoes dirt free. An example of children's shoes with built in toe cap protection method include Converse brand Chuck Taylor shoes with thick latex rubber on the toe end. Generally shoes with toe protection are those which are provided by the manufacturer and are essentially built-in or stitched onto the shoe, such as the Converse brand shoes described.

Shoe toe cap are made of different fabrics and material like leather, rubber, textiles, etc. Leather is more prone to cracking and wearing while vulcanised rubber is heavy and hard, resistant to wear and tear. Therefore, sports or hiking shoes will have toe caps made of vulcanised rubber while shoes made for day to day use will have toe caps made of leather.

Various types of shoe toe caps have already been described in the art. U.S. Pat. No 2,380,050 by Karp Jack provides an attachable toe cap for shoes, which is made of plastic material. The toe cap is stitched and then cemented to the shoe welt. There remains a risk of fracturing of the plastic material when the toe end is subjected to pressure. Also as the toe cap is cemented and stitched to the welt, any damage to the toe cap can cause considerable damage to the shoe which can be beyond repair.

US Publication No 2006/042,125 by Eddie Chen and Phoenix Hsu discloses a light weight, abrasion resistant shoe toe cap. The toe cap is made of composite material having a fabric layer and an abrasion resistant coating layer adhered to the fabric layer.

WIPO Publication No 2,013,112,022 by Tae Won Sohn and Jung Soo Yoon discloses a toe cap produced from high tenacity fibre sheet. The toe cap has sufficient load carrying capacity and impact resistance. However, the toe cap gets permanently adhered to the shoes, so if the toe cap is damaged or disfigured, it destroys the physical appeal of the shoes.

In light of the foregoing discussion, there exists a need for an innovative, robust and a durable after-market shoe toe cap which can protect the shoe from scuffing and also gives an attractive appeal to the shoes. Preferably something which does not impact the physical appearance of the shoe as purchased and vet protects the toe end, or the heel end, from damage such as scuffing, tearing, or scratches from abrasions.

SUMMARY

An object of the present invention is to provide a shoe toe cap protector, as an after-market item, which is placed on a toe end of a shoe to extend the life and appearance of the shoe. The inventive shoe toe cap protector can also be used on shoe heels or other items subject to abrasion.

The shoe toe cap is made of composite materials comprising two or more layers. A layer of an adhesive film which has a backing forms a bottom most layer of the shoe toe cap which is in contact with the toe end of the shoe. A first polyurethane film is adhered on top of the adhesive layer.

According to another embodiment, the shoe toe cap can also be provided with an additional layer for decorative purpose. The first polyurethane film can optionally be imprinted with a design for decorative purposes. The shoe toe cap is made of a first layer of the adhesive film which is placed on the toe end of the shoe, a second layer of a white or a coloured first polyurethane film with the desired imprint placed on top of the first layer, and followed by a third layer of a second polyurethane film placed over the imprinted layer. All layers adhere to each other forming the shoe toe cap.

BRIEF DESCRIPTION OF DRAWINGS

The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the scope of the claims, wherein like designations denote like elements, and in which:

FIG. 1 shows a schematic perspective view of a shoe with a shoe toe cap;

FIG. 2a shows a section of the shoe toe cap according to an embodiment of the invention; and

FIG. 2b shows a section of the shoe toe cap with the imprinted layer of the polyurethane film according to another embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

As used in the specification and claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “an article” may include a plurality of articles unless the context clearly dictates otherwise.

Those with ordinary skill in the art will appreciate that the elements in the Figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some of the elements in the Figures may be exaggerated, relative to other elements, in order to improve the understanding of the present invention.

There may be additional components described in the foregoing application that are not depicted on one of the described drawings. In the event such a component is described, but not depicted in a drawing, the absence of such a drawing should not be considered as an omission of such design from the specification.

Before describing the present invention in detail, it should be observed that the present invention utilizes a combination of system components which constitutes a shoe toe cap for prolonging the life of a shoe. Accordingly, the components and the method steps have been represented, showing only specific details that are pertinent for an understanding of the present invention so as not to obscure the disclosure with details that will be readily apparent to those with ordinary skill in the art having the benefit of the description herein.

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention.

A schematic perspective view of a shoe 100 with a shoe toe cap 102 is shown in FIG. 1 according to an embodiment of the invention. The shoe toe cap 102 adheres to a toe end 104 of the shoe 100. The shoe toe cap 102 prolongs the life of the shoe 100. The shoe toe cap 102 provides high abrasion resistance, high tear strength and prevents scuffing of the material of the shoe 100. It should be appreciated that the shoe toe cap 102 can also be used to protect any other portion of the shoe 100 such as a heel end of the shoe 100 or other vulnerable areas of the shoe. The shoe toe cap 102 can also be designed to enhance the attractive appeal of the shoe 100 by imprinting it with various designs and colours.

According to an embodiment the shoe toe cap 102 is specifically designed as an after-market product. However, it should be appreciated that the application of the shoe toe cap 102 is not limited so as to be used only as an after-market item. It can also be placed on a shoe before it is finally constructed and hence can be a “before market” application item. It should also be appreciated that the use of the shoe toe cap 102 is not restricted to shoes and footwear. The shoe toe cap 102 can also be used to protect other items such as carry bags, luggage, transport boxes, briefcases, and purses which are prone to abrasion and scuffing.

A sectional view of the shoe toe cap 102 is shown in FIG. 2a and FIG. 2 b. The shoe toe cap 102 includes a first layer 106 and a second layer 108 as shown in FIG. 2a according to an illustrative embodiment of the invention. The first layer 106 is an adhesive film 106 which has a backing for ease in transport and handling. The second layer 108 is a first polyurethane film 108. The first layer 106 is adhered on top of the toe end 104 of the shoe 100. The second layer 108 is adhered on the top of the first layer 106.

According to another embodiment of the invention, the shoe toe cap 102 is provided with an imprinted layer as shown in FIG. 2 b. The shoe toe cap 102 with imprint comprises at least three layers. The imprinting is optional and is done primarily to enhance the attractive and aesthetic appeal of the shoe 100. The three layers include the first layer 106 of the adhesive film 106, the second layer 108 of the first polyurethane film 108 having a design thereon, and a third layer 110 the third layer is preferably clear to not alter the imprint, or it can also be imprinted to accompany the first layer imprint on the shoe. Generally, the second layer 108 is imprinted with a design for decorative purposes. The second layer 108 has a white or a coloured backing onto which a design is imprinted. The backing can be made of polyurethane or a number of other thin films which are suitable for imprinting.

The third layer 110 is adhered on the top of the second layer 108 as shown in FIG. 2 b. The third layer 110 is a second polyurethane film 110. The third layer 110 is adhered on top of the imprinted second layer 108 so as to ensure that the design is not impaired or scrubbed away in event of scuffing of the shoe 100. It should be appreciated that the term first layer 106 and the term adhesive film 106 can be interchangeably used throughout the course of this disclosure. It should also be appreciated that the term second layer 108 and the term first polyurethane film 108 can be interchangeably used throughout the course of this disclosure. It should also be appreciated that the term third layer 110 and the term second polyurethane film 110 can be interchangeably used throughout the course of this disclosure. In another embodiment, the shoe toe cap 102 can be made of more than three layers. Optionally for example, an adhesive layer can be placed between the two polyurethane films to allow for greater adhesion and scuff protection.

According to an embodiment of the present invention, the first polyurethane film 108 and the second polyurethane film 110 are preferably made of aliphatic polyurethane as they tend to be more durable, less yellowing, and longer lasting than the aromatic or other polyurethanes. The use of any other suitable materials for preparing the first polyurethane film 108 and the second polyurethane film 110 is well within the scope of this invention. The adhesive film 106, the first polyurethane film 108 and the second polyurethane film 110 are transparent so that the shoe design is not impacted, and the aesthetic feature of the invention remains. Also if a user desires an imprinted design for the shoe toe cap 102, the user can see the design on the first polyurethane film 108. However, as mentioned above, the second polyurethane film can also be imprinted.

The shoe toe cap 102 can either be temporarily adhered or permanently adhered to the toe end 104 of the shoe 100. The shoe toe cap 102 is placed on the top layer of the toe end 104 of the shoe 100 and an outline of the toe end 104 of the shoe 100 is traced on the shoe toe cap 102. The shoe toe cap 102 is cut as per the outline traced. A backing paper covering the adhesive film 106 is removed and the shoe toe cap 102 is adhered to the toe end 104 of the shoe 100. It is preferable but not mandatory to apply heat, with a blow dryer or iron, while applying pressure to the toe cap.

In an alternate description, when the shoe toe cap 102 is used without an imprinted design, there are at least two layers present to form the shoe toe cap 102: the first layer 106 being an adhesive which sticks to the toe end 104 of the shoe 100, and the second layer 108 which is a polyurethane and sticks to the first layer 106. When the shoe toe cap 102 is used with an imprint, there are at least three layers present: the first (adhesive) layer 106 which sticks to the toe end 104 of the shoe 100, the second (polyurethane) layer 108 having an imprint thereon which sticks to the first layer 106 and the third (clear polyurethane) layer 110 which sticks to the second layer 108. Again, multiple layers can be used and imprinted as desired.

In yet another embodiment of the present invention the shoe toe cap include a second adhesive layer (not shown) placed between the second layer 108 and the third layer 110.

The shoe toe cap 102 of the present invention can be used on shoes made of a variety of different fabrics. Examples include Nylon (89% nylon, 17% metallic), Polyester (100%), Leather, Linen (100%), Cotton (100%), Rayon and Vinyl (100%). It should be appreciated the shoe toe cap 102 can also be used on fabrics or textiles suitable for shoes or shoe construction, other than the above mentioned examples. The shoe fabric can be anything which the polyurethane and adhesive will stick and remain on the shoe for protection of the toe cap. Laboratory testing for tensile strength, creep and taber abrasion has been conducted on the seven fabrics mentioned above after they were adhered to the shoe toe cap 102. Each fabric adhered to the shoe toe cap 102 was treated as a separate specimen and was individually tested. Results indicated that the inventive toe cap protected the fabric from scrapes, scuffs, and abrasion while remaining adhered throughout.

Tables 1-4 attached herein show the samples as submitted and as tested. Portions of the data are reproduced within the body of the specification for ease of review.

The tensile strength test (tables 2 and 3) for each of the specimen was conducted under conditions before and after applying heat at 60 degree Celsius. Each specimen was subjected to 180° peel at a constant rate of 50 mm/minute under both the conditions. The results of the tensile strength test before heating and after heating are as follows:

Tensile Strength Testing, Before Heating Sample

Peel Strength Before Heating Peak Load (lbf) (lbf/in) 89% Nylon 17% 1.46 0.992 Metallic 100% Polyester 1.86 1.229 Leather 2.573 2.159 100% Linen 1.08 0.664 100% Cotton 5.13 3.068 Rayon 2.415 2.156 100% Vinyl 2.426 1.965

Tensile Strength Testing, After Heating Sample

Peel Strength After Heating (60° C.) Peak Load (lbf) (lbf/in) 89% Nylon 17% 2.236 1.691 Metallic 100% Polyester 2.777 1.879 Leather 1.882 0.931 100% Linen 1.494 1.128 100% Cotton 5.014 2.809 Rayon 3.995 3.065 100% Vinyl 1.791 1.449 For tensile strength, it was found the strength increased after heating for nylon, polyester, linen, and rayon. The tensile strength decreased after heating for leather, cotton and vinyl.

The creep test for each of the specimen was conducted under conditions subjected to oven aging at 40° C. and by increasing the temperature by 10° C. every hour until it reaches 60° C. It was observed that for all specimens there was no creepage of the shoe toe cap 102 which was adhered to the fabric or material. Creep data is shown in Table 1. The taber abrasion test for each of the specimen was conducted under conditions subjected to abrasion testing using a 500 g load and CS-10 wheels for 250 cycles. It was observed that no specimen exhibited wear through the shoe toe cap 102 to the material. Taber abrasion data is shown in Table 4.

For the present examples and data collected, fabrics as discussed above were employed. The adhesive used was a 3M Company supplied adhesive number 9472LE which is employed on the adhesive transfer tape and has a low surface energy acrylic adhesive providing high bond strength to most surfaces. It was found to be suitable for fabrics having light contamination with machine oil parts such as found on after-market shoes of cloth or leather or synthetic fabrics.

It was found to have excellent to good adhesion onto the surfaces employed. The technical data for adhesive 300LSE and in particular number 9472LE can be found on the 3M website, herein incorporated by reference. Film 9472LE has a 5.2 mil (132 micron) thickness, 58# polycoated kraft liner, the adhesive is solvent free and acrylic based. This adhesive has: good bond strength, humidity resistance after exposure for 7 days at 90 F (32 C) and 90% humidity, water has no appreciable effect on the bond strength after 100 hours at room temperature, the bond is maintained, chemical resistance to oil, mild acids and alkalis, and has a lower service temperature to about −40 F (−40 C).

The polyurethane used was as supplied by API (American Polyfilm, Inc.) of Branford, Conn., USA. It was supplied as PN 1001, aliphatic polycaprolactone-base polyurethane, having the following values:

Polyurethane PN 1001 Specification

Test Values ASTM Method Durometer 92A D2240 Specific gravity 1.12 D792 Elongation at break 380% D412 Tensile strength at 6000 psi D412 break 100 o/o Modulus 1000 psi D412 300 o/o Modulus 4500 psi D412 Tear strength  460 psi D624 Melt range 195-250° F.

The polyurethane film was reported to have exceptional clarity, good UV stability and high hydrolysis resistance per API.

The present invention has been described herein with reference to a particular embodiment for a particular application. Although selected embodiments have been illustrated and described in detail, it may be understood that various substitutions and alterations are possible. Those having ordinary skill in the art and access to the present teachings may recognize additional various substitutions and alterations are also possible without departing from the spirit and scope of the present invention, and as defined by the following claim. 

1. A shoe toe cap comprising: a first layer adhering on top of a toe end of a shoe, wherein the first layer is an adhesive film; and a second layer adhering on the top of the first layer, wherein the second layer is a polyurethane film.
 2. The shoe toe cap of claim 1, wherein the first layer is temporarily adhered on the top of the toe end of the shoe.
 3. The shoe toe cap of claim 1 wherein the first layer is permanently adhered on the top of the toe end of the shoe.
 4. The shoe toe cap of claim 1, wherein the polyurethane film is made of aliphatic polyurethane.
 5. The shoe toe cap of claim 1, wherein the shoe toe cap is used on shoes made of a fabric from at least one of Nylon, Polyester, Leather, Linen, Cotton, Rayon and Vinyl.
 6. The shoe toe cap of claim 1, wherein the shoe toe cap is shaped to adhere to the toe end and heel end of the shoe.
 7. The shoe toe cap of claim 1, wherein the shoe toe cap has tensile strength in the range of 1.08 lbf to 5.13 lbf.
 8. The shoe toe cap of claim 1, wherein the shoe toe cap is resistant to creep and abrasion.
 9. A shoe toe cap comprising: a first layer adhering on top of a toe end of a shoe, wherein the first layer is an adhesive film; a second layer adhering on top of the first layer, further comprising a first polyurethane film having an imprint thereon, and a second polyurethane film on top of the first imprinted polyurethane film.
 10. The shoe toe cap of claim 9, wherein the first layer is temporarily adhered on the top layer of the toe end of the shoe.
 11. The shoe toe cap of claim 9, wherein the first layer is permanently adhered on the top layer of the toe end of the shoe.
 12. The shoe toe cap of claim 9, wherein the first polyurethane film and the second polyurethane film are made of aliphatic polyurethane.
 13. The shoe toe cap of claim 9, wherein the shoe toe cap is used on shoes made of a fabric from at least one of Nylon, Polyester, Leather, Linen, Cotton, Rayon and Vinyl.
 14. The shoe toe cap of claim 9, wherein the second polyurethane film layer is imprinted with a design for decorative purpose.
 15. The shoe toe cap of claim 9, wherein the shoe toe cap is shaped to adhere to the toe end and heel end of the shoe.
 16. The shoe toe cap of claim 9, wherein the shoe toe cap has tensile strength in the range of 1.08 lbf to 5.13 lbf.
 17. The shoe toe cap of claim 9, wherein the shoe toe cap is resistant to creep.
 18. The shoe toe cap of claim 9, wherein the shoe toe cap is resistant to abrasion.
 19. The shoe toe cap of claim 1, wherein the shoe toe cap is placed on a shoe before the shoe is finally constructed.
 20. The shoe toe cap of claim 1, wherein the shoe toe cap is placed on one of a carry bag, luggage, transport boxes, briefcase and purse. 